Husqvarna 4421-DXL User Manual Download

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HUV 4421 Owner’s Manual

4421-G/GX/GXL Gas and

4421-D/DX/DXL Diesel Utility Vehicles

[Refer to back cover for applicable build code range]

Summary of Contents for 4421-DXL

Page 1: ...HUV 4421 Owner s Manual 4421 G GX GXL Gas and 4421 D DX DXL Diesel Utility Vehicles Refer to back cover for applicable build code range ...

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Page 3: ...damages that result from the use of the material in this manual This manual contains proprietary information that is protected by copyright All rights are reserved No part of this manual may be photocopied reproduced or translated to another language without the written consent of Husqvarna Inc The information contained in this document is subject to change without notice Husqvarna reserves the ri...

Page 4: ...support system designed to offer you fast courteous service In the event that your Husqvarna vehicle needs repairs or service we recommend that your local authorized Husqvarna representative perform them For the name and address of the Husqvarna representative nearest you logon to our web site at www usa husqvarna com If you would prefer to write to us direct your letter to Husqvarna Attention Mar...

Page 5: ...2 Driving Instructions 23 Bed Latch and Prop Rod 26 Loading and Unloading Cargo 27 Vehicle Load Capacities 28 Towing with the Vehicle 29 Transporting on a Trailer 29 Storage 30 Maintenance 32 Periodic Service Schedule 33 Periodic Lubrication Schedule 36 Brake Fluid Reservoir 38 Engine Oil 39 Gearcase Lubrication 44 Engine Coolant Diesel Vehicles 46 Air Intake System 47 Fueling Instructions 48 Batt...

Page 6: ...Vehicle Specifications 56 Warranties 59 Page 4 HUV 4421 Owner s Manual ...

Page 7: ... SAFETY DECAL AND FEATURE IDENTIFICATION The following pages contain safety decal and feature identification information For detailed information on specific features read the appropriate section in this manual HUV 4421 Owner s Manual Page 5 ...

Page 8: ...ody below seat 7 102459201 Decal Diesel Fuel Warning on frame near fuel tank 3 102427501 Decal Hot Pressurized Fluid Warning on coolant reserve tank cap under hood 8 102459501 Decal Rotating Hot Parts Warning on frame near battery 4 102458901 Decal Hot Surface Warning on coolant pipes and underside of seats on bed seal 9 102884301 Decal Operating Instructions on instrument panel 5 102459001 Decal ...

Page 9: ...d 8 102961201 Decal ROPS Warning on ROPS 3 102224001 Decal Rotating Parts Warning on frame 9 103202601 Decal Vehicle Loading Instructions on cargo bed 4 102459301 Decal Bed Latch Warning on vehicle body below bed latch 10 103210401 Decal Vehicle Loading Instructions on cargo bed for vehicles with the high capacity option 5 102459401 Decal Young Driver Warning on ROPS 11 Serial Number 6 102460201 D...

Page 10: ... seat 7 102459201 Decal Diesel Fuel Warning on frame near fuel tank 3 102427501 Decal Hot Pressurized Fluid Warning on coolant reserve tank cap under hood 8 102459501 Decal Rotating Hot Parts Warning on frame near battery 4 102458901 Decal Hot Surface Warning on coolant pipes and underside of seats on bed seal 9 102460201 Decal Rotating Parts Warning Diesel Only on vehicle body under seat 5 102459...

Page 11: ...ng behind seat near cargo bed 8 102889201 Decal Falling Off Warning behind and below front seats 3 102224001 Decal Rotating Parts Warning on frame 9 102961201 Decal ROPS Warning on ROPS 4 102459301 Decal Bed Latch Warning on vehicle body below bed latch 10 103210501 Decal Vehicle Loading Instructions on cargo bed 5 102459401 Decal Young Driver Warning on ROPS 11 Serial Number 6 102884301 Decal Ope...

Page 12: ...e information in this manual Understand and become familiar with the DANGER WARNING and CAUTION statements and procedures it contains along with the safety decals that are affixed to your vehicle Take time to understand the language of safety It is a language that can save your life PROPOSITION 65 STATE OF CALIFORNIA WARNING This product contains or emits chemicals or substances that have been det...

Page 13: ...e practice that could result in minor personal injury CAUTION A CAUTION without the safety alert symbol indicates a potentially hazardous situation that could result in property damage GENERAL WARNINGS The following safety statements must be heeded whenever the vehicle is being operated repaired or serviced See Safety Decal and Feature Identification on page 5 Other specific safety statements appe...

Page 14: ... prop rod ensure that it is securely engaged while bed is raised Do not close bed until all persons are clear of cargo bed area Keep hands clear of all crush areas Do not drop cargo bed lower gently and keep entire body clear Failure to heed this warning could result in severe personal injury or death Only trained technicians should service or repair the vehicle Anyone doing even simple repairs or...

Page 15: ...ry Terminal Protector Spray CCI P N 1014305 to minimize corrosion 4 Gasoline Vehicles Only Connect the spark plug wire s to the spark plug s RECYCLING LEAD ACID BATTERIES WARNING Lead acid batteries contain lead Pb other metals acids and other compounds If improperly handled they can contaminate both water and soil causing environmental damage and personal injury Lead acid batteries are identified...

Page 16: ...er indicate the vehicle model The following four digits 2 indicate the model year and production week during which the vehicle was built The six digits 3 following the hyphen represent the unique sequential number assigned to each vehicle built within a given model year See following NOTE NOTE Have the vehicle serial number available when ordering parts or making inquiries A 17 digit Product Infor...

Page 17: ...damage the engine and other components and could result in property damage personal injury or death due to unsafe speeds Do not shift the Forward Reverse handle while the vehicle is in motion Engine must be at idle before shifting the Forward Reverse handle Failure to do so may result in injury to inattentive passengers and or damage to the vehicle To avoid unintentionally starting or rolling the ...

Page 18: ...Indicators 9 6 11 1 3 2 B A C 7 8 13 4 5 12 15 14 192 Figure 6 Instrument Panel Gasoline Vehicles 9 6 11 1 3 2 B A C 7 10 8 13 4 5 12 15 193 Figure 7 Instrument Panel Diesel Vehicles Page 16 HUV 4421 Owner s Manual ...

Page 19: ...the PREHEAT position longer than 20 seconds To preheat the glow plugs in cold weather turn the key to the PREHEAT position and hold it there for 10 15 seconds Then turn the key to the START position and hold it there until the engine starts If the engine does not start after 10 15 seconds turn the key to the OFF position and repeat the procedure Once the engine starts release the key and it will r...

Page 20: ...following WARNING WARNING The park brake has multiple locking positions and should be firmly locked to prevent the vehicle from rolling 4 191 Figure 8 Park Brake Release STEERING ADJUSTMENT LOCK The steering wheel position is adjustable To adjust the steering wheel position press down on the steering adjustment lock lever 5 then move the steering wheel to the desired position Figure 6 and Figure 7...

Page 21: ...osition and allows the operator to monitor the fuel level in the vehicle The hour meter operates only when the engine is running and should be used by the trained technician to track vehicle usage and determine when periodic service procedures are required See Periodic Service Schedule on page 33 HEADLIGHT CONTROL The headlight control 12 is located on the left side of the instrument panel Figure ...

Page 22: ...afety belt should be worn securely and as low as possible over the hips and not on the waist Injured person Depending on the injury first check with your doctor for specific recommendations To secure the safety belt sit up straight and well back in the seat Pull the safety belt out of the retractor and insert the tab into the buckle A click will be heard when the tab locks into the buckle Position...

Page 23: ...ld in his or her lap while the vehicle is moving This vehicle is not designed to meet child seat compatibility requirements Children requiring a child safety seat must not ride on the vehicle Comply with state and local laws pertaining to child safety CAUTION Be careful not to damage the safety belt webbing or hardware Inspect the safety belt system periodically Check for cuts fraying and loose pa...

Page 24: ...d easily See Safety Decal and Feature Identification on page 5 ROPS Check to ensure the ROPS is not damaged and all hardware is secure See Roll Over Protective Structure and Seat Belts on page 20 Seat belts Visually inspect for cuts fraying and loose parts See Roll Over Protective Structure and Seat Belts on page 20 Tires Check for proper tire pressure Visually inspect tires for wear damage and pr...

Page 25: ...osition Accelerator After starting the engine with the key switch and placing the Forward Reverse handle in the FORWARD position the vehicle should accelerate smoothly to full speed as the accelerator pedal is pressed When the pedal is released it should return to the original position and the engine should idle This vehicle operates at a reduced speed in reverse Governor Check maximum vehicle spe...

Page 26: ...g control of or overturning the vehicle reduce speed for adverse driving conditions such as wet grass or rough terrain Do not use the vehicle on public roads It is neither designed nor intended for street use and should not be licensed for use on public roads The vehicle should be driven in only specified areas by trained drivers Do not drive while under the influence of alcohol drugs or medicatio...

Page 27: ...er shift the vehicle out of the FORWARD position while going downhill If you do you will not be able to shift into the REVERSE position or back into the FORWARD position until stopped Press the brake pedal as necessary and press the accelerator pedal partially when descending a hill With the accelerator pedal partially pressed the governor will cause the engine to assist the brakes in controlling ...

Page 28: ...2 Turn the key switch to the OFF position remove the key and place the Forward Reverse handle in the NEUTRAL position BED LATCH AND PROP ROD See General Warnings on page 11 The bed latch Figure 10 has an automatically engaging prop rod and prop rod track Figure 11 as standard features To lift the bed pull the bed latch handle toward the rear of the vehicle and lift the bed The prop rod will come t...

Page 29: ...rain Do not exceed rated vehicle capacity Rated capacity is for level surfaces only Overloading can affect vehicle handling or cause component failure resulting in loss of control of vehicle and possible severe personal injury or death Do not load tailgate The tailgate should be in the upright position and latched securely while the vehicle is in motion To help avoid shifting vehicle load and poss...

Page 30: ...ed the vehicle s stated maximum payload capacity Vehicle Rated Capacity The vehicle rated capacity is the maximum amount of weight the vehicle can carry haul and tow This capacity includes weight of occupants bed load and gross trailer weight Maximum Gross Vehicle Weight The maximum gross vehicle weight is the combination of the vehicle weight and the maximum vehicle capacity The stated maximum gr...

Page 31: ...overturn possibly resulting in severe personal injury Towing another vehicle or a trailer can have adverse effects on vehicle handling Be especially cautious when towing other equipment with this vehicle See Vehicle Load Capacities on page 28 for vehicle capacity information Parking the vehicle with a trailer on a hill should be avoided If you must park on a hill apply the brakes and have someone ...

Page 32: ...ust be transported over long distances or on public highways it should be transported on an approved trailer that has an approved load rating of 2000 lb 908 kg per vehicle being transported See following NOTE NOTE A two car trailer should be rated at 2 x 2000 lb 4000 lb 2 x 908 kg 1816 kg STORAGE See General Warnings on page 11 DANGER Do not attempt to drain fuel when the engine is hot or while it...

Page 33: ... the tank with fresh fuel 4 2 Following the manufacturer s directions add a commercially available fuel stabilizer such as Sta Bil Run the engine in a well ventilated area to allow treated fuel to replace untreated fuel in the carburetor 4 3 Disconnect the fuel vent line from the fuel tank vent nipple Figure 34 4 4 Plug the fuel tank vent nipple so that it is air tight Husqvarna recommends using a...

Page 34: ...l shut off valve combined with the use of the choke can result in a fouled spark plug and engine failure 5 Place the Forward Reverse handle in the NEUTRAL position Crank the engine until fuel is pumped into the carburetor gasoline vehicles and the fuel lines all vehicles and the engine starts Turn the engine off See following NOTE NOTE Due to the oil added to the gasoline engine in preparation for...

Page 35: ...he vehicle disconnect battery and spark plug Gas only wires See Disconnecting the Battery Gasoline Diesel Vehicle on page 13 If wires are removed or replaced make sure wiring and wire harness are properly routed and secured Failure to properly route and secure wiring could result in vehicle malfunction property damage personal injury or death Lift only one end of the vehicle at a time Use a suitab...

Page 36: ...necessary See Vehicle Specifications on page 56 Transmission and differentials Check lubricant levels Add if necessary See Lubrication Level Check for Front Differential Transmission and Rear Differential on page 44 Monthly service by owner or trained technician General vehicle Wash engine compartment and underside of vehicle Do not wash engine when hot Battery Clean terminals and wash dirt from c...

Page 37: ...m Section in the maintenance and service manual Radiator Diesel vehicles Check clamps for tightness check hoses for cracks Replace if necessary Replace air filter element See Air Intake System on page 47 Engine air intake system Check clamps for tightness check hose for cracks General vehicle Check for loose hardware and tighten if necessary Annual service by trained technician only or every 100 h...

Page 38: ...ician Driveshaft 2 Chassis Lube EP NLGI Grade 2 Semiannually by owner or trained technician or every 50 hours of operation whichever comes first Rear suspension 2 fittings Chassis Lube EP NLGI Grade 2 First change 50 hours additional change every 100 hours of operation or annually whichever comes first Change front differential lubricant 5 oz 150 mL Mobil 424 Exxon Hydraul 560 or Esso Hydraul 56 l...

Page 39: ...Periodic Lubrication Schedule 5 6 3 1 4 2 2 3 199 Figure 15 Lubrication Points Gasoline Vehicles 5 6 3 1 4 2 2 3 200 Figure 16 Lubrication Points Diesel Vehicles HUV 4421 Owner s Manual Page 37 ...

Page 40: ...inspect the following The presence of brake fluid on the exterior surface of the master cylinder indicates a leak The brake fluid reservoir diaphragm located in the cap should not have holes or other damage BRAKE FLUID Brake fluid level should be within 1 4 inch 6 mm from the top of the reservoir Figure 18 Also brake fluid should be clean with no residue in the bottom of the reservoir or other evi...

Page 41: ...Kawasaki engine manual is 35 45 psi at idle however the remote filter design causes oil pressure to be 18 psi which is normal for this type of oil circulation design ENGINE OIL LEVEL CHECK 1 Remove the oil level dipstick from the oil filler tube and wipe oil from the dipstick Figure 19 and Figure 20 See following CAUTION CAUTION Do not remove dipstick while engine is running 2 Check oil level by f...

Page 42: ...as only wires See Disconnecting the Battery Gasoline Diesel Vehicle on page 13 3 Remove the oil filler cap to allow the oil to drain properly 4 Position a pan designed for oil changes under the drain plug Figure 21 or Figure 22 5 From the underside of the vehicle use a socket or wrench to remove the drain plug 1 Turn the plug counterclockwise and drain the engine oil into the pan See following WAR...

Page 43: ...ne Oil Drain Plug and Pan Gasoline Vehicles 208 Figure 22 Engine Oil Drain Plug and Oil Filter Diesel Vehicles 2 210 Figure 23 Replace Engine Oil Filter Kawasaki Gasoline Vehicles Engine Oil Filter Change 1 Drain the engine oil See Engine Oil Draining on page 40 2 Place the oil drain pan under the engine oil filter 2 Figure 22 or Figure 23 3 Remove the engine oil filter Turn it counterclockwise an...

Page 44: ...the oil filter forming a channel to direct the filter port oil into the drain pan Dispose of used oil according to the environmental laws and regulations for your area 26 Figure 24 Remove Engine Oil Filter 27 Figure 25 Coat Rubber Seal 4 Use a clean rag to wipe the oil filter mounting bracket surface clean where the oil filter gasket seats 5 Coat filter gasket with clean engine oil Figure 25 6 Ins...

Page 45: ...er cap 4 Connect battery and spark plug Gas only wires See Connecting the Battery Gasoline Diesel Vehicle on page 13 5 With the Forward Reverse handle in the NEUTRAL position start and run the engine for three minutes and check for leaks Observe both the drain plug and the oil filter from under the vehicle and watch for oil leaks If the filter leaks tighten an additional 1 4 turn and retest If the...

Page 46: ...se the lower plug 2 for drainage Figure 30 Figure 31 or Figure 32 Remove both plugs to allow the lubricant to drain faster See preceding NOTE Metal particles may be discovered in the fluid or on the magnetic drain plug when changing the differential or transmission fluid These particles are normal and expected for the first few fluid changes This is a result of the gears being net forged meaning t...

Page 47: ...tite 567 to the threads of the fill plug and tighten to 21 ft lb 28 N m Check the level of lubricant at the level indicator plug 1 Apply Loctite 567 to the threads of the level indicator plug and tighten to 21 ft lb 28 N m Rear differential Clean and install the drain plug 2 and washer before filling the rear differential with new lubricant Figure 32 Tighten the drain plug to 96 in lb 10 8 N m Use...

Page 48: ...ure 17 Raise the hood to check the coolant level before every operation 1 Check the coolant level of the reserve tank 2 If the coolant is at or below the LOW mark add pre mixed coolant until the level reaches the FULL mark If a leak is detected have it checked by a trained technician See following WARNING WARNING Hot Coolant reserve tank is pressurized Do not remove cap when engine is hot Page 46 ...

Page 49: ... roughly running engine service the air filter immediately Air Filter Removal 1 Raise the cargo bed and locate the air filter canister 2 Release both canister tab locks Figure 33 3 Pull the canister cap away from the canister 4 Remove the air filter cartridge 1 See following NOTE NOTE The air filter cartridge is specifically designed for this engine It only fits into the canister one way Use only ...

Page 50: ...ehicles have a green fuel cap See preceding DANGER and following NOTE NOTE Gasoline vehicles Use unleaded gasoline only Whenever possible avoid using oxygenated fuels and fuels that are blended with alcohol Diesel vehicles Use only diesel fuel grade no 2 with a cetane rating of 45 or higher 2 Replace the fuel cap Ensure that the cap is tightened securely 3 Clean any spilled fuel from the cap or ar...

Page 51: ...iesel is used be sure to apply the following guidelines Ensure the fuel tank is as full as possible at all times to prevent moisture from collecting Ensure that the fuel tank cap is securely tightened to prevent water from entering the fuel tank Drain all water from the fuel filter daily before operating vehicle See Draining Water from Fuel Filter Check the engine oil level daily before the engine...

Page 52: ...ns for your area 1 221 Figure 36 Fuel Filter BATTERY See General Warnings on page 11 DANGER Battery Explosive gases Do not smoke Keep sparks and flames away from the vehicle and service area Ventilate when charging or operating vehicle in an enclosed area Wear a full face shield and rubber gloves when working on or near batteries Battery Poison Contains acid Causes severe burns Avoid contact with ...

Page 53: ...tenance battery that requires infrequent checks Figure 37 Electrolyte level should be checked semiannually NEG POS 1 3 2 1 Level Indicator 2 Cap 3 Plates Electrolyte level at least 1 2 inch 13 MM above plates or to level indicator 222 Figure 37 Battery 22 Figure 38 Battery Electrolyte Level 1 Turn the key switch to the OFF position and remove the key Place the Forward Reverse handle in the NEUTRAL...

Page 54: ...Wear a full face shield and rubber gloves when working on or near batteries When jumping from a booster battery make final connection negative at engine frame Do not jump start or charge a frozen or damaged battery Unplug charger before connecting or disconnecting cables to the battery Never lean over battery while boosting testing or charging If it is necessary to use a booster battery to start t...

Page 55: ...aner paste and fine grade No 00 steel wool The manufacturer does not recommend any type of pressure washing or steam cleaning Such a process will expose electrical components to moisture Moisture entering electrical components can result in water damage and subsequent component failure Use non abrasive wax products Battery acid fertilizers tars asphalt creosote paint or chewing gum should be remov...

Page 56: ...fixed to the vehicle on the seat support panel next to the receptacle for the remote operation switch The winch kit available includes a remote operation switch which enables the operator to move away from the vehicle and cable See following WARNING and CAUTION WARNING Before beginning a winch operation Turn key switch to the OFF position put Forward Reverse handle in the NEUTRAL position and enga...

Page 57: ...ccording to the directional arrow mark arrow indicates forward rotation of the tire on the side wall of each tire or the tread performance will be severely compromised The tires are made specifically for the AWD vehicle therefore Husqvarna recommends that only tires purchased from Husqvarna be used on your AWD vehicle SUBSEQUENT OWNER REGISTRATION In the event a vehicle is bought as a used vehicle...

Page 58: ...on Forward and reverse with neutral 5 39 1 forward 7 79 1 reverse Electrical system 12 volt 500 cca at 0 F 17 8 C 650 at 32 F 0 C 105 minute reserve capacity and 35 amp charging capacity Torque converter Automatic variable speed dry type STEERING SUSPENSION BRAKES Suspension Front Independent double A arms with coil over shock absorbers Rear Swing arms with coil over shock absorbers Steering Self ...

Page 59: ...m h Governed RPM 3825 Turning Radius 138 in 350 5 cm 204 in 518 2 cm Load bed height 34 in 86 4 cm Load bed size box bed inside dimensions 48 0 x 49 8 x 10 9 in 122 x 127 x 28 cm 15 3 cubic feet Maximum payload capacity level surface only 800 lb 363 kg High capacity option 1050 lb 476 kg 800 lb 363 kg Vehicle rated capacity payload driver and passenger level surface only 1200 lb 544 kg High capaci...

Page 60: ...l 56 lubricant 20 oz 600 mL Engine coolant mixture of 55 propylene glycol and 45 water n a 2 gal 7 8 L n a 2 25 gal 8 5 L Brake fluid DOT 5 silicone brake fluid 8 oz 240 ml 17 9 oz 530 ml Fuel tank unleaded gasoline 6 5 gallons 24 6 L 6 5 gallons 24 6 L Fuel tank diesel grade no 2 with cetane rating of 45 or higher 6 5 gallons 24 6 L 6 5 gallons 24 6 L TIRE PRESSURE All terrain tread and mud tires...

Page 61: ...shoes belts brushes bushings drive buttons engine mounts mats and pads maintenance adjustments cosmetic deterioration and items which deteriorate or fail due to exposure or ordinary wear and tear Batteries battery charger onboard computer and solid state speed controller are covered under separate Husqvarna warranties Also excluded from any Husqvarna warranty is damage to a vehicle or component re...

Page 62: ...tial damages Therefore the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state 8 INFORMATION For further information customers in Europe and all other countries except for the US should go to www Husqvarna com Customers in the U S should contact HUSQVARNA PROFESSIONAL PRODUCTS INC WARRA...

Page 63: ...e warranty period stated above Any such part repaired or replaced under warranty will be warranted for the remaining original warranty period 3 Any warranted part that is scheduled for replacement as required maintenance in the written instructions supplied is warranted for the period of time before the first scheduled replacement date for that part If the part fails before the first scheduled rep...

Page 64: ...anister Mounting Brackets Carbon Canister Purge Port Connector Misc Parts Belts hosing tubing fittings seals gaskets clamps and switches associated with the above systems Emission related parts will vary between vehicles therefore certain vehicles may not include all of the listed parts or may include equivalent parts 3 VOIDING OF WARRANTY THIS AND ANY OTHER WARRANTY SHALL BE VOID IF THE VEHICLE I...

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Page 68: ...ber 103472526 Edition Code 0708D1010C 103472526 This manual is valid for vehicles built during the 2009 model year It is also valid for vehicles with build codes between 54699 and the one indicated at the top of this page ...

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